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LIST OF EFFECTIVE PAGES

CHAPTER SECTION LEP

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DATE Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003 Nov 28/2003

Contents

Introduction

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TABLE OF CONTENTS SUBJECT INTRODUCTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. General Organization Method of Use Customer Support Pratt and Whitney Canada Accessories Services Supplementary Publications Suppliers and Supplier Services Safety Consumable Materials Directional References Module/Assembly Denition Abbreviations and Symbols Special Tools Special Tool Service Bulletins Denition of Terms A. B. C. D. E. F. Bodie Check Detailed Inspection Economic Life Hard Time Opportunity Inspection Refurbishment 1 1 2 3 3 3 5 5 5 5 5 5 11 13 13 13 13 13 13 13 14 14 14 14 14 PAGE

G. Refurbishment limit (Previously Called Overhaul Limit) H. I. J. Repair Repair Limit Service Limit

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TABLE OF CONTENTS SUBJECT INTRODUCTION (Contd) K. L. Soft Time Visual Inspection 14 14 PAGE

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INTRODUCTION 1. General A. This overhaul manual, supplied by Pratt & Whitney Canada, contains recommended procedures for the overhaul and repair of PW124B (BS724/726/896) PW127 (BS774), PW127E (BS850/BS1034) and PW127F (BS918/BS1033) turboprop engines. Any discrepancies, problems or suggestions regarding this publication should be forwarded in writing, using the Pratt & Whitney Canada Customer Feedback Sheet (RSVP), and directed to: Pratt & Whitney Canada Corp. 1000 Marie-Victorin Longueuil, Quebec Canada J4G 1A1 Attention: Manager, Publications Dept. (01PB4) FAX: (450) 647-2702 Website: www.pwc.ca E-mail: Publications@pwc.ca NOTE: 1. A new on-line RSVP form is available via the P&WC website at (http://www.pwc.ca). NOTE: 2. Customer Feedback Sheets are enclosed with new manuals and each subsequent revision. Additional forms may be obtained by contacting: The Supervisor, Customer Services, at the above address. 2. Organization This manual is organized in Chapter/Section/Unit format to comply with the requirements of Specication ATA 100 of the Air Transport Association of America as follows: Chapter/Section/Unit 72-00-00 Engine (General) 72-01-00 Externals and Accessories 72-01-10 Electrical System Components 72-01-20 Ignition System Components 72-01-30 Air System Components 72-01-40 Fuel System Components 72-01-50 Oil System Components 72-01-60 Performance Indicating System Components 72-02-00 RGB/TMM Separation/Joining 72-03-00 Turbomachinery 72-10-00 Reduction Gearbox 72-20-00 Inlet Section 72-30-00 Compressor Section

B.

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72-40-00 Combustion Section 72-50-00 Turbine Section Chapter 72-00-00 Consists of: Description and operation of the engine. Engine external cleaning and general cleaning information. Engine inspection general information. Engine repairs of a general nature - e.g. stud, helical coil, shanknut, pin replacement. Engine ts and clearances in respect of module assembly and installation. Engine testing and fuel and oil system preservation. Engine storage and shipping instructions for engine and modules. Light overhaul instructions, including instructions following receipt of engines removed for unscheduled inspection. Section 72-01-00 and units 72-01-10 through 72-01-60 provide instructions for removal, overhaul and installation of external components of the following engine systems: electrical, ignition, air, fuel, oil and performance indicating. Section 72-02-00 provides instructions for separation and joining of the reduction gearbox and turbomachinery module. Section 72-03-00 provides instructions for disassembling and assembling the turbomachinery. Sections 72-10-00 through 72-50-00 provide overhaul instructions for the following engine sections: reduction gearbox, inlet, compressor, combustion and turbines. Functional heading page blocks have been designated as follows: Heading Description and Operation Disassembly Cleaning Inspection Repair Final Assembly/Subassembly Fits and Clearances Testing Troubleshooting Storage Instructions Light Overhaul 3. Method of Use To use this manual, determine which module or assembly of the engine is involved, refer to the Contents page(s) in that section of the manual, locate the item in the Subject column and turn to the indicated page. Page Block 1-99 101-199 201-299 301-399 401-499 501-599 601-699 701-799 801-899 901-999 1301-1399

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4.

Customer Support Customer Support representatives maintain contact with operators and service activities and are available for investigation of any specic difficulty or problem. Requests for assistance and/or AOG (Aircraft on Ground) support should be directed to: Pratt & Whitney Canada Corp. 1000 Marie Victorin Blvd. Longueuil, Quebec Canada J4G 1A1 Attention: Customer Support TEL: US and Canada: 1-800-268-8000 International: (IAC)-8000-268-8000 Other: 1-450-647-8000 FAX: 1-450-647-2888 E-mail: customerhelpdesk@pwc.ca

5.

Pratt and Whitney Canada Accessories Services You can send your accessories for repair, full overhaul and/or other information, questions, technical support to the Pratt and Whitney Canada Accessories Services at the addresses that follow: TABLE 1, Accessories Services addressess Shipping Address for the Accessories (Repair & Overhaul) P&WC Accessories Services 333 Rue dAuvergne (Area 2K) Longueuil, Quebec Canada J4H 3Y3 TEL: 450-442-6837 Mailing Address for Information, Questions, Technical Support P&WC Accessories Services 1000 Marie-Victorin Blvd. (Mail Stop 01PB4) Longueuil, Quebec Canada J4G 1A1 TEL: 450-647-2720 FAX: 450-647-3851

6.

Supplementary Publications The following publications are also required for effective overhaul of the engine. A. B. C. Engine Illustrated Parts Catalog, Part No. 3037334, lists and describes parts available and illustrates their relationships. Facility Planning Manual, Part No. 3040878, describes and illustrates the facilities required. Pratt & Whitney Overhaul Standard Practices Manual (SPM), Part No. 585005, provides information applicable to all Pratt & Whitney Aircraft products and details the SPOPs mentioned in this publication. This manual is available from the following address:

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Commercial Parts Support Pratt & Whitney Aircraft Commercial Products Division 400 Main Street East Hartford, CT 06108 USA Attention: Supervisor, Distribution D. E. CIR Manual P/N 3043515, covers the cleaning, inspection and repair of all engine components. Accessories Component Maintenance Manuals. Component maintenance manuals for both P&WC and supplier furnished accessories are referenced in this manual. For more information, refer to Illustrated Parts Catalog (IPC). Data Reduction Program Manual, Part No. 30P10974, provides the program for converting test cell readings to standard day conditions.

F.

G. Turbine Disk Riveting Fixture Information and Operating Instructions (PWC31900) provides operating instructions for xture (PWC31892) on turbine disk riveting. H. I. J. K. Operating instructions (PWC38399) provides information for xture (PWC38296) on turbine blade rivet removal. For details on the method of using Borescope (PWC34910) for internal visual inspections of the engine, refer to section 72-00-00, ENGINE - INSPECTION. Anti-friction Bearings Overhaul Visual Inspection Manual, P/N 3039731, contains standardized inspection criteria and nomenclature for all bearings. Care, Cleaning and Handling of Anti-friction Bearings Manual, P/N 3040337, contains basic guidelines to prevent damage or contamination of anti-friction bearings in an overhaul environment. Service Bulletins (1) Engine Service Bulletins are issued as needed to provide information relating to the engine, parts or other useful data. The bulletins are issued in sequence of ATA 72 identiers and are prexed PW100-TP (e.g. PW100-TP-72-1 or PW100-72-21111) to indicate their applicability to the PW100 turboprop family. Service Bulletins for all PW100 models are available as a set under Part No. 3034650. For a set of Service Bulletins exclusive to the PW124B (BS724/726/896)/PW127 (BS774)/PW127E (BS850/BS1034)/PW127F (BS918/BS1033) series, order Part No. 3037036 . NOTE: References to Service Bulletins in the text of this manual are to P&WC in-house SB numbers - e.g. SB20007. Refer to the Service Bulletin List for cross-references to the ATA 72 identiers.

L.

M. Time Limits/Maintenance Checks (1) The applicable Maintenance Manual lists all parts with a predetermined life cycle, and species the maximum service life of these parts.

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N. 7.

The Consumable Material List, P/N 3043340, contains complete information for the consumable material item numbers referenced in this book.

Suppliers and Supplier Services For a list of the names and addresses of suppliers, refer to the PW100 CIR, P/N 3043515. The names of any companies provided in the PW100 CIR, as possible sources of required services or supplies, are furnished for informational purposes only. Pratt & Whitney Canada has tested and approved the specialized repairs identied in the manual and the repair shops whose Supplier Codes appear in the CIR. However, the performance of any repair is solely the responsibility of the repairer and P&WC provides no warranty and accepts no responsibility for any such repairs.

8.

Safety This publication describes processes that require use of chemicals, solvents, paints and other commercially available materials. Users of this publication should obtain the material safety data sheets (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Users must adhere to the manufacturer/supplier information for the safe use, handling, storage and disposal of these materials.

9.

Consumable Materials WARNING: MATERIAL SAFETY DATA SHEETS (MSDS) CONTAINING INFORMATION ABOUT TRADE NAME, SAFETY HAZARDS, HEALTH HAZARDS, REACTIVITY, SPILL OR LEAK PROCEDURES, SPECIAL PROTECTION INFORMATION, SPECIAL PRECAUTIONS, AND TRANSPORTATION AND LABELLING ARE AVAILABLE FROM MANUFACTURER. READ PRIOR TO USING CONSUMABLE MATERIAL. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR ILLNESS.

For a complete list of consumable materials used in the repair of the engine, refer to the Consumable Material List (P/N 3043340). 10. Directional References Throughout this manual, all references to direction or location apply to the engine when mounted horizontally and viewed from the rear, unless stated otherwise. 11. Module/Assembly Denition The engine comprises two modules: reduction gearbox and turbomachinery. An engine-supplied module is a functional unit that carries its own serial number, Build Specication and identication data plate and is complete, less accessories installed by the airframe manufacturer. An assembly is a basic unit of the engine, less accessories and most external parts. 12. Abbreviations and Symbols A. The following abbreviations are used throughout this manual:

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AC ACC AFU ALT AMS ATA A.T.O. BDC BRG BS BTU C cc cc/hr. CIR CMM CML CCW CL CLA cm/s Cond. CW daN DC DEL DELMOP DELRTH Dia. DTI ECU EEC EECP emf ESHP F F&C Fed. Spec. Fig.(s) FIR FI FLGD

Alternating Current Accessory Autofeather Unit Alternator Aerospace Material Specication Air Transport Association Alternate Take Off Bottom Dead Center Bearing Build Specication British Thermal Unit(s) Degree(s) Celsius (Centigrade) Cubic Centimeter(s) Cubic Centimeter(s) per hour Cleaning/Inspection/Repair Manual Component Maintenance Manual Consumable Material List Counterclockwise Class Condition Lever Angle Centimeters per second (Velocity) Condition Clockwise Dekanewton(s) Direct Current Delta Delta Main Oil Pressure Delta Root Theta Diameter Dial Test Indicator Electronic Control Unit (as indicated on EECP) Electronic Engine Control (Electronic Fuel Control) Engine Electronic Control Panel Electromotive Force Equivalent Shaft Horsepower Degree(s) Fahrenheit Fits and Clearances Federal Specication Figure(s) Full Indicator Reading Flight Idle Flanged

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FOD FPI FWD GI Gov. GOV gph gpm GSHFT HD HDLS HP hr. HSG HSI HYD IAC ID IGN in. in. Hg. in. H2O IND IPC kg kg/hr. kPa kPad kPag kV l/h. l/min. lb. lbf.in. lbf.ft. lb./hr. L/E LH LHV LMC LP lph (l/hr)

Foreign Object Damage Fluorescent Penetrant Inspection Forward Ground Idle Governing Governor Gallons per hour Gallons per minute Gearshaft Headed Headless High Pressure Hour(s) Housing Hot Section Inspection Hydraulic International Access Code Inside Diameter Ignition Inch(es) Inch(es) of Mercury Inch(es) of Water Indicator Illustrated Parts Catalog Kilogram(s) Kilogram(s) per Hour Kilopascal(s) Kilopascal(s) delta Kilopascal(s) gage Kilovolt Liters per hour Liters per minute Pound(s) Pound(s) force/inch Pound(s) force/foot Pound(s) per Hour Leading Edge Left Hand Lower Heating Value BTU/lb Least Material Condition Low Pressure Liters per Hour

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Man. Max. MAX MCL MCP MCR MEK MFCU MIL min. Min. MIN mm MMC MOP MOT MPI MRB MS N NBLG NBLP NDT NH NL Nm NORM NP NPT OD O/S oz. PAM Pamb PC PC/g PC/mc2 Pc PCU Pd Perf. Pg

Manual Maximum Maximum Maximum Climb Maximum Continuous Power Maximum Cruise Methyl-Ethyl-Ketone Mechanical Fuel Control Unit Military Specication Minute(s) Minimum Minimum millimeter(s) Maximum Material Condition Main Oil Pressure Main Oil Temperature Magnetic Particle Inspection Maintenance Review Board (Material) Military Standard Newton(s) Normal Backlash on Gear Normal Backlash on pinion Nondestructive Testing High Pressure Rotor Speed Low Pressure Rotor Speed Newton Meter(s) Normal Propeller Speed (Power Turbine Rotor Speed (rpm)) Power Turbine Speed Outside Diameter Oversize Ounce(s) Corrected Barometric Pressure (in.Hg.) Ambient Pressure Pico-Coulomb Accelerometer Charge Sensitivity (Imperial Units) Accelerometer Charge Sensitivity (Metric Units) Compressor Discharge Pressure Propeller Control Unit Pressure Differential Performance Exhaust Static Pressure (psia)

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PL PLA PMC P/N P/O pph PSN Prop. PRV PS psi psia psid psig P1 P1.5 P1.8 P2 P2.5 P3 Ps3 PS2.5 PS8 PSN PT Pt pt Px Py PWA PWC P&WC PWR Q R RDCD RDCN Ref. REF. NO. REV RFS

Power Lever Power Lever Angle Process Material Control Part Number Part of Pound(s) per Hour Test Cell Static Pressure (in.H2O) Propeller Pressure Regulating Valve Process Solution Pound(s)/square inch Pound(s)/square inch (absolute) Pressure Differential (between oil delivery pressure and pressure in Nos. 3 and 4 bearing cavity - in psi Pound(s)/square inch (gage) Air Inlet Pressure Inlet Lip Pressure (psia) Total Inlet Pressure LP Compressor Inlet Pressure Compressor Pressure (station 2.5) Compressor Pressure (station 3) Compressor Delivery Pressure (psia) High Pressure Compressor Inlet Pressure (in.Hg.) Exhaust Gas Static Pressure (in.H2O) Test Cell Static Pressure (in.H2O) Power Turbine Total Inlet Pressure Fuel Inlet Pressure (psig) Enrichment Pressure Governor Servo Pressure Pratt & Whitney Aircraft Pratt & Whitney Canada tooling prex Pratt & Whitney Canada Power Management Dynamometer Torque (lbf.ft.) (Nm) Degree(s) Rankine (F + 459.688) Reduced Reduction Reference or Refer to Reference Number (Fits and Clearances) Reverse Regardless of Feature Size

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RGB RH rpm RTH RTNG RTNR RTV RVDT SB SCU sec. SFC SG SG (Base) SHLDRD SHP (shp) SHP (shp) NOTE:

Reduction Gearbox Right Hand Revolutions per minute Root Theta Retaining Retainer Room Temperature Vulcanizing Rotary Variable Differential Transformer Service Bulletin(s) Speed Control Unit Second(s) Specic Fuel Consumption Specic Gravity (of fuel) Turbine Meter Calibration Standard Shouldered Shaft Horsepower (Q x NPT/80748) (Dynamometer) Shaft Horsepower (TORQ x NP/5354) (Engine)

SPMC SPOP Target Torque TBA TBO TDC TDP Temp. T/E TF TH TIG TMM TORQ To T.O. T.O.P. TSG Ts3 Tt1 Tt8

The constant 5354 used above, is derived by taking into consideration power losses due to friction in RGB. Service Process Material Control Service Process Operation Procedure Calculated Torque for Set Conditions To Be Advised Time Between Overhauls Top Dead Center Dew Point Temperature, C (F) Temperature Trailing Edge Fuel Temperature Theta Tungsten Inert Gas (welding method) Turbomachinery Module Engine Torquemeter (lbf.ft.) (Nm) Total Inlet Pressure (Temperature) Take-off Take-off Power SG Fuel Sample Temperature F Compressor Delivery Temperature Inlet Lip Temperature F Exhaust Gas Temperature F/R

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T1.8 T6 T6C T6H T6T V VDC W Wf B. 13.

Total Inlet Temperature Interturbine Temperature Interturbine Temperature (calculated) F/R Interturbine Temperature (harness) (untrimmed) F/R Interturbine Temperature (trimmed) F/R Volt(s) Volt(s), Direct Current Watt(s) Fuel Flow (pph)

The following symbols (Ref. Fig. 1) are used on illustrations throughout this manual. For more information, refer to SPM.

Special Tools Requests for the purchase of the special tools specied in this publication should be sent to one of the following companies, depending on the customers geographic location: Kell-Strom Tool Co. Inc. (CAGE 75245) 214 Church Street Wetherseld, CT 06109 USA TEL: 860-529-6851, or 1-800-851-6851 (USA & Canada), or 860-721-0658 (24 hour service) FAX: 860-257-9694 Website: www.kell-strom.com E-mail: lpriest@kell-strom.com Groupe Rasakti Inc. (CAGE 3AD21) 3000 Rue Power Drummondville, Quebec Canada J2C 6H9 TEL: 819-474-3366 (regular & 24 hour service), or 1-888-727-2584 (USA & Canada) FAX: 819-474-3055 Website: www.rasakti.com E-mail: c.marcoux@rasakti.com Pratt & Whitney Tool Support Services (CAGE 77445) 411 Silver Lane (M/S 129-20) East Hartford, CT 06118 USA TEL: 860-610-2675 or 860-565-0140 (24-hour service number) 1-800-PWA-TOOL (792-8665) (USA & Canada) FAX: 860-610-2670 E-mail: lemirejw@pweh.com

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SYMBOL

CHARACTERISTIC

SYMBOL

CHARACTERISTIC

STRAIGHTNESS

PARALLELISM

FLATNESS

PERPENDICULARITY

PROFILE OF LINE

CIRCULAR RUNOUT

PROFILE OF SURFACE

ANGULARITY

ROUNDNESS

CONCENTRICITY

CYLINDRICITY

TRUE POSITION

C31522 Form and Position Characteristic Symbols Figure 1

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Pratt & Whitney Canada, Tooling Solutions (CAGE 00198) 333 rue dAuvergne (02AN1) Longueuil, Quebec Canada J4H 3Y3 TEL: 450-442-5400 (regular & 24-hour service number) 1-800-3-115-5122 (USA, Canada & International) FAX: 450-442-5420 Website: www.pwctoolingsolutions.com E-mail: henri.hudon@pwc.ca or frank.caruso@pwc.ca 14. Special Tool Service Bulletins Special Tool Service Bulletins (STSBs) are issued to modify special tooling. These bulletins apply only to the tool part number and indicate the engine model family on which the tool is used. STSBs are issued on colored stock. Upon receipt, STSBs should be checked as to their application. STSBs are available as a set under Part No. 3034555. 15. Denition of Terms Whenever possible, World Airlines Technical Operations Glossary (WATOG) denitions, supplemented if necessary, were used when preparing this document. A. Bodie Check A very rapid (slam) acceleration followed by a rapid (slam) deceleration of the power lever. B. Detailed Inspection An intensive visual check of a specied detail, assembly or installation carried out to detect evidence of damage or irregularity using concentrated lighting and, where necessary, inspection aids such as mirrors, borescope, etc. Surface cleaning and elaborate access procedures may also be required. C. Economic Life Economic life is the life at which module refurbishment produces the lowest operating costs within airworthiness limitations. D. Hard Time Hard time is when the engine/modules are refurbished at xed intervals. E. Opportunity Inspection An opportunity inspection may be carried out when the engine/module/component is removed for other reasons. The inspection consists of visual/dimensional checks which can involve disassembly, cleaning, reassembly and test procedures necessary to discover defects undetectable by on-wing inspection.

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F.

Refurbishment To restore an engine or engine module to ensure cost-effective operation is achieved. Refurbishment of a module is the accomplishment of all disassembly, cleaning, inspection, repair (or replacement of parts as required), restoration of ts and clearances, reassembly and test procedures necessary to enable the full operational life of the module to be re-established. Engines incorporating refurbished modules will have the test and performance requirements covered by the applicable overhaul manual.

G. Refurbishment limit (Previously Called Overhaul Limit) Refurbishment limits are those limits which guarantee the full operational life of the component. H. Repair Repair makes an item serviceable by replacing or processing failed or damaged parts. Repair of an engine/module is the accomplishment of limited strip, cleaning, inspection, processing (or replacement) of parts, reassembly and test as necessary to restore the engine to operational status. I. Repair Limit The repair limit is the most economically viable t/clearance/dimension obtained after repair/replacement, which does not affect engine residual life, to the next refurbishment (e.g. Hot Section Inspection Limits). J. Service Limit The service limit is the maximum limit to which components can deteriorate in service without requiring repair or replacement. These limits are used when carrying out an opportunity inspection or repair. K. Soft Time Soft time is the recommended minimum time a module may stay in service before refurbishment. Modules reaching the specied soft time do not have to be removed from the engine but may be removed for refurbishment at any subsequent time when the engine/module is removed from the aircraft. Soft time will be used when dening the extent of work required during a shop visit. L. Visual Inspection External surveillance inspection to detect obvious unsatisfactory conditions/discrepancies.

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